Vent shield for a battery module

ABSTRACT

The present disclosure relates generally to a battery module having a housing and a stack of battery cells disposed in the housing. Each battery cell has a battery cell terminal and a battery cell vent on an end of each battery cell, and the battery cell vent is configured to exhaust effluent into the housing. The battery module has a vent shield plate disposed in the housing and directly along an immediate vent path of the effluent, a first surface of the vent shield plate configured to direct the effluent to an opening between the shield plate and the housing, and a second surface of the vent shield plate opposite the first surface. The battery module also has a venting chamber coupled to the opening and at least partially defined by the second surface and a vent configured to direct the effluent out of the battery module.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from and the benefit of U.S.Provisional Application Ser. No. 62/100001, entitled “MECHANICAL ANDELECTRICAL ASPECTS OF LITHIUM ION BATTERY MODULE WITH VERTICAL ANDHORIZONTAL CONFIGURATIONS,” filed Jan. 5, 2015, which is herebyincorporated by reference.

BACKGROUND

The present disclosure relates generally to the field of batteries andbattery modules. More specifically, the present disclosure relates to avent shield for a battery module.

This section is intended to introduce the reader to various aspects ofart that may be related to various aspects of the present disclosure,which are described below. This discussion is believed to be helpful inproviding the reader with background information to facilitate a betterunderstanding of the various aspects of the present disclosure.Accordingly, it should be understood that these statements are to beread in this light, and not as admissions of prior art.

A vehicle that uses one or more battery systems for providing all or aportion of the motive power for the vehicle can be referred to as anxEV, where the term “xEV” is defined herein to include all of thefollowing vehicles, or any variations or combinations thereof, that useelectric power for all or a portion of their vehicular motive force. Forexample, xEVs include electric vehicles (EVs) that utilize electricpower for all motive force. As will be appreciated by those skilled inthe art, hybrid electric vehicles (HEVs), also considered xEVs, combinean internal combustion engine propulsion system and a battery-poweredelectric propulsion system, such as 48 Volt (V) or 130V systems. Theterm HEV may include any variation of a hybrid electric vehicle. Forexample, full hybrid systems (FHEVs) may provide motive and otherelectrical power to the vehicle using one or more electric motors, usingonly an internal combustion engine, or using both. In contrast, mildhybrid systems (MHEVs) disable the internal combustion engine when thevehicle is idling and utilize a battery system to continue powering theair conditioning unit, radio, or other electronics, as well as torestart the engine when propulsion is desired. The mild hybrid systemmay also apply some level of power assist, during acceleration forexample, to supplement the internal combustion engine. Mild hybrids aretypically 96V to 130V and recover braking energy through a belt or crankintegrated starter generator. Further, a micro-hybrid electric vehicle(mHEV) also uses a “Start-Stop” system similar to the mild hybrids, butthe micro-hybrid systems may or may not supply power assist to theinternal combustion engine and operate at a voltage below 60V. For thepurposes of the present discussion, it should be noted that mHEVstypically do not technically use electric power provided directly to thecrankshaft or transmission for any portion of the motive force of thevehicle, but an mHEV may still be considered an xEV since it does useelectric power to supplement a vehicle's power needs when the vehicle isidling with internal combustion engine disabled and recovers brakingenergy through an integrated starter generator. In addition, a plug-inelectric vehicle (PEV) is any vehicle that can be charged from anexternal source of electricity, such as wall sockets, and the energystored in the rechargeable battery packs drives or contributes to drivethe wheels. PEVs are a subcategory of EVs that include all-electric orbattery electric vehicles (BEVs), plug-in hybrid electric vehicles(PHEVs), and electric vehicle conversions of hybrid electric vehiclesand conventional internal combustion engine vehicles.

xEVs as described above may provide a number of advantages as comparedto more traditional gas-powered vehicles using only internal combustionengines and traditional electrical systems, which are typically 12Vsystems powered by a lead acid battery module. For example, xEVs mayproduce fewer undesirable emission products and may exhibit greater fuelefficiency as compared to traditional internal combustion vehicles and,in some cases, such xEVs may eliminate the use of gasoline entirely, asis the case of certain types of EVs or PEVs.

As technology continues to evolve, there is a need to provide improvedpower sources, particularly battery modules, for such vehicles and otherimplementations. For example, battery modules may be subject to releasesof pressurized gas from electrochemical cells to prevent issues relatedto accumulated pressure within the cells. It is now recognized thatimproved techniques for venting gases from battery modules may bedesirable to avoid issues associated with accumulation of gases in thebattery module. For example, in certain configurations, the vented gasesmay be expelled from the electrochemical cells near module components,which may be negatively impacted by the temperature and/or compositionof the vented gases. Accordingly, it may be desirable to mitigate suchnegative impacts by re-directing a flow of the gases out of the batterymodule.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. Itshould be understood that these aspects are presented merely to providethe reader with a brief summary of these certain embodiments and thatthese aspects are not intended to limit the scope of this disclosure.Indeed, this disclosure may encompass a variety of aspects that may notbe set forth below.

The present disclosure relates to a battery module that includes ahousing and a first stack of battery cells disposed in the housing,wherein each battery cell of the first stack of battery cells comprisesa battery cell terminal and a battery cell vent, the battery cellterminal and the battery cell vent are on an end of each battery cell,and the battery cell vent is configured to exhaust battery cell effluentinto the housing. Additionally, the battery module has a first ventshield plate disposed in the housing and directly along an immediatevent path of the battery cell effluent, a first surface of the firstvent shield plate configured to direct the battery cell effluent to anopening between an edge of the first shield plate and the housing, and asecond surface of the first vent shield plate opposite the firstsurface. The battery module also includes a venting chamber fluidlycoupled to the opening and at least partially defined by the secondsurface and a vent fluidly coupled to the venting chamber and configuredto direct the battery cell effluent out of the battery module.

The present disclosure also relates to a battery module that includes astack of lithium-ion battery cells disposed in a housing, wherein eachlithium-ion battery cell of the stack of lithium-ion battery cellscomprises a battery cell terminal and a battery cell vent, the batterycell terminal and the battery cell vent are on an end of eachlithium-ion battery cell, and the battery cell vent is configured toexhaust battery cell effluent into the battery module. The batterymodule also has a vent shield plate disposed directly along an immediatevent path of the battery cell effluent, a first surface of the ventshield plate configured to direct the battery cell effluent to anopening between an edge of the shield plate and the housing, and asecond surface of the vent shield plate opposite the first surface.Finally, the battery module has a vent structure configured to directthe battery cell effluent out of the battery module, a venting chamberof the vent structure fluidly coupled to the opening and at leastpartially defined by the second surface, and a vent of the ventingstructure fluidly coupled to the venting chamber.

The present disclosure further relates to a battery module that includesa housing and a receptacle of the housing configured to receive a stackof battery cells, wherein each battery cell of the stack of batterycells has an end comprising a battery cell terminal and a battery cellvent, and the battery cell vent is configured to exhaust battery celleffluent. The battery module also has an integrated sensing and bus barsubassembly positioned directly along a vent path of the battery celleffluent, a carrier of the integrated sensing and bus bar subassembly, abus bar of the integrated sensing and bus bar subassembly integratedonto the carrier and configured to electrically couple battery cells ofthe stack of battery cells in an electrical arrangement, a sensor of theintegrated sensing and bus bar subassembly disposed on the bus bar andconfigured to enable sensing of a voltage across the bus bar or sensingof a temperature at the bus bar, and a vent shield plate of theintegrated sensing and bus bar subassembly disposed on the carrierbetween the battery cells of the stack of battery cells and the sensordisposed on the bus bar. The vent shield plate is configured to absorbkinetic energy and thermal energy from the battery cell effluent and todirect the battery cell effluent to an opening in the integrated sensingand bus bar subassembly. Finally, the battery module includes a modulecover disposed over the integrated sensing and bus bar subassembly andagainst the housing, wherein the module cover and the integrated sensingand bus bar subassembly at least partially define a venting chamberconfigured to receive the battery cell effluent after the battery celleffluent has passed through the opening, and wherein the module covercomprises a vent configured to direct the battery cell effluent out ofthe battery module.

DRAWINGS

Various aspects of this disclosure may be better understood upon readingthe following detailed description and upon reference to the drawings inwhich:

FIG. 1 is a perspective view of an xEV having a battery systemconfigured to provide power for various components of the xEV, inaccordance with an aspect of the present disclosure;

FIG. 2 is a cutaway schematic view of an embodiment of the xEV thatutilizes the battery system of FIG. 1, in accordance with an aspect ofthe present disclosure;

FIG. 3 is an illustration of a battery module that may include a ventshield to block battery cell effluent from contacting and/or overheatingsensitive electrical components in the battery module, in accordancewith an aspect of the present disclosure;

FIG. 4 is an illustration of an embodiment of an individual battery cellthat may be included in the battery module of FIG. 3, in accordance withan aspect of the present disclosure;

FIG. 5 is an illustration of an embodiment of an integrated sensing andbus bar subassembly that may be included in the battery module of FIG.3, in accordance with an aspect of the present disclosure;

FIG. 6 is an illustration of an embodiment of the integrated sensing andbus bar subassembly of FIG. 5 with a carrier, shield plates, and a busbar, in accordance with an aspect of the present disclosure;

FIG. 7 is an illustration of an embodiment of the integrated sensing andbus bar subassembly of FIG. 6 with the carrier removed to show theposition of the shield plate, in accordance with an aspect of thepresent disclosure;

FIG. 8 is an illustration of the battery module of FIG. 3 with a vent, ahousing, and a housing cover, in accordance with an aspect of thepresent disclosure;

FIG. 9 is an illustration of an embodiment of the battery module ofFIGS. 3 and 8 with the battery module housing made transparent, inaccordance with an aspect of the present disclosure;

FIG. 10 is an illustration of an embodiment of a vent path of thebattery cell effluent, in accordance with an aspect of the presentdisclosure;

FIG. 11 is an illustration of another embodiment of the vent path of thebattery cell effluent, in accordance with an aspect of the presentdisclosure; and

FIG. 12 is a top view of the battery cell effluent vent path of FIG. 11,in accordance with an aspect of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effortto provide a concise description of these embodiments, not all featuresof an actual implementation are described in the specification. Itshould be appreciated that in the development of any such actualimplementation, as in any engineering or design project, numerousimplementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which may vary from one implementation toanother. Moreover, it should be appreciated that such a developmenteffort might be complex and time consuming, but would nevertheless be aroutine undertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure.

Battery modules, in accordance with the present disclosure may beconfigured to release pressurized gases into the housing of the batterymodule. For example, the electrochemical cells may be susceptible toincreases in heat, during normal and/or abnormal operation, causing anincrease in internal pressure. Vents may be integrated into theelectrochemical cells to enable the release of the pressurized gases.However, because the battery modules often include temperature sensitivecomponents (e.g., electronics, sensors), the pressurized gases may bedirected out of the battery module via a desired venting path tomitigate any damage to the sensitive battery module components.

Accordingly, the battery module housing may include a vent structure(e.g., vent shield, venting chamber, vent, module cover, housing, etc.)configured to direct pressurized gases away from the electrochemicalcells and other temperature sensitive components along the venting path.For example, a vent chamber may be aligned with the electrochemical cellvents to collect and receive the vented gases. Moreover, the ventchamber may be fluidly connected to an internal portal to direct thegases through a guiding chamber for expulsion out of the battery module.In certain embodiments, the vent chamber includes recesses configured toreceive plates. For example, the plates may be configured to redirectthe flow of pressurized gases toward the internal portal. Moreover, thevent structure may be configured to couple to a cover of the batterymodule to further direct flow of the pressurized gases out of thebattery module. In some embodiments, the vent structure may be at leastpartially defined by the battery module housing.

The present disclosure includes embodiments of a battery module having avent shield configured to block gases vented from the electrochemicalcells from contacting and/or overheating electrical components disposedwithin a general direction in which the gases are ejected. Althoughdiscussion of the present disclosure is mainly focused on batterymodules that include lithium ion battery cells, it should be noted thatthe disclosed embodiments may be used in any battery moduleconfiguration that may benefit from the present techniques.

To help illustrate, FIG. 1 is a perspective view of an embodiment of avehicle 10, which may utilize a battery system 12 that includes one ormore vent shields described in the present disclosure. It is nowrecognized that it is desirable for the non-traditional battery system12 (e.g., a lithium ion car battery having a vent shield) to be largelycompatible with traditional vehicle designs. In this respect, presentembodiments include various types of battery modules for xEVs andsystems that include xEVs. Accordingly, the battery system 12 may beplaced in a location in the vehicle 10 that would have housed atraditional battery system (e.g., a standard 12V lead acid battery or a12V lithium ion battery with no vent shield). For example, asillustrated, the vehicle 10 may include the battery system 12 positionedsimilarly to a lead-acid battery of a combustion-engine vehicle (e.g.,under the hood of the vehicle 10).

A more detailed view of the battery system 12 is described in FIG. 2. Asdepicted, the battery system 12 includes an energy storage component 14coupled to an ignition system 16, an alternator 18, a vehicle console20, and optionally to an electric motor 22. Generally, the energystorage component 14 may capture/store electrical energy generated inthe vehicle 10 and output electrical energy to power electricalcomponents in the vehicle 10. Additionally, the energy storage component14 may output electrical energy to start (e.g., re-start or re-ignite)an internal combustion engine 24. For example, in a start-stopapplication, to preserve fuel, the internal combustion engine 24 mayidle when the vehicle 10 stops. Thus, the energy storage component 14may supply energy to re-start the internal combustion engine 24 whenpropulsion is demanded by the vehicle 10.

The battery system 12 may also supply power to components of thevehicle's electrical system, which may include radiator cooling fans,climate control systems, electric power steering systems, activesuspension systems, auto park systems, electric oil pumps, electricsuper/turbochargers, electric water pumps, heated windscreen/defrosters,window lift motors, vanity lights, tire pressure monitoring systems,sunroof motor controls, power seats, alarm systems, infotainmentsystems, navigation features, lane departure warning systems, electricparking brakes, external lights, or any combination thereof In thedepicted embodiment, the energy storage component 14 supplies power tothe vehicle console 20 and the ignition system 16, which may be used tostart (e.g., crank) the internal combustion engine 24.

Additionally, the energy storage component 14 may capture electricalenergy generated by the alternator 18 and/or the electric motor 22. Insome embodiments, the alternator 18 may generate electrical energy whilethe internal combustion engine 24 is running More specifically, thealternator 18 may convert the mechanical energy produced by the rotationof the internal combustion engine 24 into electrical energy.Additionally, or alternatively, when the vehicle 10 includes an electricmotor 22, the electric motor 22 may generate electrical energy byconverting mechanical energy produced by the movement of the vehicle 10(e.g., rotation of the wheels) into electrical energy. Thus, in someembodiments, the energy storage component 14 may capture electricalenergy generated by the alternator 18 and/or the electric motor 22during regenerative braking. As such, the alternator and/or the electricmotor 22 are generally referred to herein as a regenerative brakingsystem.

To facilitate capturing and supplying electric energy, the energystorage component 14 may be electrically coupled to the vehicle'selectric system via a bus 26. For example, the bus 26 may enable theenergy storage component 14 to receive electrical energy generated bythe alternator 18 and/or the electric motor 22. Additionally, the bus 26may enable the energy storage component 14 to output electrical energyto the ignition system 16 and/or the vehicle console 20.

Additionally, as depicted, the energy storage component 14 may includemultiple battery modules. For example, in the depicted embodiment, theenergy storage component 14 includes a lithium ion (e.g., a first)battery module 28 and a lead acid (e.g., a second) battery module 30,which each includes one or more battery cells. Additionally, the energystorage component 14 may include any number of battery modules, all orsome of which may include protective vent shields. Although the lithiumion battery module 28 and lead-acid battery module 30 are depictedadjacent to one another, they may be positioned in different areasaround the vehicle. For example, the lead-acid battery module 30 may bepositioned in or about the interior of the vehicle 10 while the lithiumion battery module 28 may be positioned under the hood of the vehicle10.

In some embodiments, the energy storage component 14 may includemultiple battery modules to utilize multiple different batterychemistries. For example, when the lithium ion battery module 28 isused, performance of the battery system 12 may be improved since thelithium ion battery chemistry generally has a higher coulombicefficiency and/or a higher power charge acceptance rate (e.g., highermaximum charge current or charge voltage) than the lead-acid batterychemistry. As such, the capture, storage, and/or distribution efficiencyof the battery system 12 may be improved.

To facilitate controlling the capturing and storing of electricalenergy, the battery system 12 may additionally include a control module32 (e.g., a battery management system). More specifically, the controlmodule 32 may control operations of components in the battery system 12,such as relays (e.g., switches) within the energy storage component 14,the alternator 18, and/or the electric motor 22. For example, thecontrol module 32 may regulate an amount of electrical energycaptured/supplied by each battery module 28 or 30 (e.g., to de-rate andre-rate the battery system 12), perform load balancing between thebattery modules 28 and 30, determine a state of charge of each batterymodule 28 or 30, determine a temperature or voltage of each batterymodule 28 or 30 (e.g., via a signal received from one or more sensingcomponents), control voltage output by the alternator 18 and/or theelectric motor 22, and the like.

Accordingly, the control unit 32 may include one or more processor units34 and one or more memory components 36. More specifically, the one ormore processor units 34 may include one or more application specificintegrated circuits (ASICs), one or more field programmable gate arrays(FPGAs), one or more general purpose processors, or any combinationthereof. Additionally, the one or more memory components 36 may includevolatile memory, such as random access memory (RAM), and/or non-volatilememory, such as read-only memory (ROM), optical drives, hard discdrives, or solid-state drives. In some embodiments, the control unit 32may include portions of a vehicle control unit (VCU) and/or a separatebattery control module. Furthermore, as depicted, the lithium ionbattery module 28 and the lead-acid battery module 30 are connected inparallel across their terminals. In other words, the lithium ion batterymodule 28 and the lead-acid module 30 may be coupled in parallel to thevehicle's electrical system via the bus 26.

As discussed previously, the battery module 28 may experience pressurebuildup as a result of accumulation of electrochemical cell effluentgases. The battery module 28 may include components that are sensitiveto increased temperatures caused by the effluent or that may be corrodedor otherwise subject to damage caused by the chemical makeup of theeffluent. Therefore, it may be desirable to include a vent shield in thebattery module 28 to direct the effluent along a vent path that maymitigate damage to the sensitive components. It is now recognized that avent shield positioned directly along the vent path of the effluent mayabsorb a majority of thermal and kinetic energy from the effluent aswell as re-direct the effluent to a venting chamber. Although the ventshield may not completely prevent exposure of the sensitive componentsto the effluent, it may provide enhanced protection, thereby increasingthe life of the battery module 28.

FIG. 3 illustrates an embodiment of the module 28, which may include thevent shield configured to block the effluent from the electrochemicalcells from contacting and/or overheating sensitive electrical componentsin the battery module 28. The battery module 28 illustrated in FIG. 3 isintended to be representative of one application of the vent shield, andtherefore, it should be noted that the vent shield may be included inany battery module (e.g., a lead-acid battery module, a lithium-ionbattery module, etc.).

The battery module 28 may include a stack(s) of battery cells 50 and 52,where each individual battery cell 54 includes cell terminals 56 and acell vent 58. The individual battery cells 54 may be arranged in thestack 50 or 52, where the battery cells 54 are positioned adjacent toone another in orientations where their respective terminals 56 arepositioned at the same side of the stack 50 or 52. Accordingly, adjacentbattery cells 54 will have terminals 56 that are adjacent to one anotherin each battery cell stack 50 and 52. As an example, the embodimentillustrated in FIG. 3 includes two side-by-side cell stacks 50 and 52,which may be referred to as a first cell stack 50 and a second cellstack 52.

As shown in FIG. 3, the battery module 28 may include a module housing60 constructed of any appropriate material, such as an amide-basedpolymer, a polyolefin (e.g., polypropylene), or any other material. Themodule housing 60 includes a cell receptacle region 62, where thebattery cell stacks 50 and 52 are positioned within the battery modulehousing 60. In the illustrated embodiment, the battery cells 52 arepositioned into the cell receptacle region 62 “bottom first,” where theterminals 56 and vents 58 of each battery cell 54, positioned on whatmay be referred to as a “top” end of the cells 54, point outwardlytoward an opening 64 of the receptacle region 62.

To facilitate discussion of the present embodiments, FIG. 4 illustratesan embodiment of the individual battery cell 54 of a battery module 28in accordance with present embodiments to introduce certain terminologyused herein to refer to portions of the battery cells 54. In a prismaticcell configuration, as shown in FIG. 4, the battery cells 54 include atop portion 66 having at least one cell terminal 56 (the illustratedembodiment has two cell terminals on the top 66) and a cell vent 58 forallowing pressurized gas to escape during a venting situation. Theillustrated battery cell 54 of FIG. 4 also includes first 68 and second70 faces, corresponding to the broadest part of a casing 72 of thebattery cells 54. A bottom part 74 is substantially opposite the toppart 66, and may, in some embodiments, include a cell vent 58 in lieu ofthe cell vent 58 on the top part 66. The faces 68 and 70 extend betweenthe top 66 and bottom 74 portions, and are coupled by first 76 andsecond 78 sides, which may be straight, rounded, or any other suitablegeometry. The casing (housing) 72 of the battery cell, which houses theactive electrochemical elements of the cell 54, may be polymeric,metallic, composite, or any other suitable material. Further, it shouldbe noted that the present embodiments are not limited to battery modules28 having prismatic battery cell configurations, but are also intendedto include embodiments where the battery cells 54 are pouch batterycells, cylindrical battery cells, and so forth. Furthermore, whiledescribed in the context of a lithium ion battery module 28 havinglithium ion battery cells 54, the present disclosure is applicable toother battery chemistries (e.g., lead acid battery cells) that may besubject to venting in the manner described herein.

Additionally, the battery module 28 may include an integrated sensingand bus bar subassembly 80 (“subassembly” or “bus bar subassembly”), asillustrated in FIG. 5. The bus bar subassembly 80 may be positionedadjacent to the top portions 66 of the battery cells 54, therebyenabling the subassembly 80 to electrically interconnect the batterycells 54 in a predetermined relationship via bus bars 82. Theinterconnection of the battery cells 54 in this manner may enable aplurality of series and/or parallel connections to be made, resulting ina predetermined voltage and/or capacity of the overall battery module28. In certain embodiments (e.g., the embodiment of FIG. 3), the batterymodule 28 may have, for example, six battery cells 54 connected inseries to produce a voltage output that is the sum of the individualvoltages of the battery cells, and a capacity substantially equal to thecapacity of an individual cell 54. Other electrical connections, such asone or more parallel connections, would affect the voltage and capacity.In other embodiments, the battery module 28 may include less than sixbattery cells (e.g., 5, 4, 3, 2, or 1) or more than six battery cells(e.g., 7, 8, 9, 10, 12, 15, 20, 25, 30, 35, 40, 45, 50, or more).

In addition to forming the electrical connections using the bus bars 82of the subassembly 80, the subassembly 80 also includes various sensingfeatures 84 (e.g., sensing components, sensors, or the like) configuredto enable the control unit 32 (e.g., controller or battery managementsystem “BMS”) of the module 28 to perform monitoring functions withrespect to the battery cells 54 and the module 28. The sensing features84 (e.g., sensing components, sensors, or the like), as depicted in FIG.5, include voltage sense components 86, which are configured to sensevoltages at each bus bar 82, as well as temperature sense components 88,which are configured to sense temperatures at certain bus bars 82. Thesesensing components 84 are coupled to cabling 90 configured to carrysignals generated by the sensing components 84 to the control unit 32(e.g., the BMS). For example, the sensing features 84 may beelectrically coupled to the control unit 32 (e.g., via the cabling 90)and configured to send signals pertaining to a temperature or a voltageof the battery module 28 over time. In certain embodiments, the controlunit 32 may include a threshold temperature and/or voltage value storedin the memory components 36. If a signal received from the sensingfeatures 84 exceeds the threshold value, the control unit 32 may beconfigured to disconnect a flow of electricity between the batterymodule 28 and a load, for example.

In certain embodiments, the bus bars 82, the temperature 88 and voltage86 sense components, and the cabling 90 are all integrated onto acarrier 92, which may form a one-piece structure (e.g., the subassembly)configured to carry and integrate these components. Additionally, thecarrier 92 may also include one or more vent shields configured todirect the battery cell effluent along a desired vent path.

As may be appreciated with reference to FIGS. 3-5, the general directionof the cell 54 venting may cause vented gases (e.g., heated CO₂, heatedvaporized solvent) to contact and/or heat the various electroniccomponents on the carrier 92, thereby causing the sensing components 84,the cabling 90, or both, to degrade. Additionally or alternatively, theconnection of the sensing components 84 to the bus bars 82 can also bedegraded upon exposure to the vented gases. To mitigate these unwantedeffects, one or more shielding features may be integrated into thebattery module 28, as will be described in more detail with reference toFIG. 6.

FIG. 6 is an embodiment of the carrier 92 from a back perspective view,where a first shield plate 100 and a second shield plate 102 areintegrated into a carrier assembly 104, which includes the carrier 92,the shield plates 100 and 102, and the bus bars 82. Other components notexplicitly illustrated may also be included in the carrier assembly 104.In accordance with present embodiments, the first 100 and second 102shield plates are located on a portion 106 of the carrier thatcorresponds to a position between the vents 58 of the battery cells 54and some or all of the electrical components (e.g., the sensingcomponents 84 and cabling 90). More specifically, the first shield plate100 may be located within a vent path 108 of the first cell stack 50,thereby blocking effluent from the battery cells 54 of the first stack50 from contacting the carrier 92 and heating the electrical componentsof the subassembly 80. Similarly, the second shield plate 102 is locatedwithin a vent path 110 of the second cell stack 52, thereby blockingeffluent from the battery cells 54 of the second stack 52 fromcontacting the carrier 92 and heating the electrical components of thesubassembly 80. The carrier 92 also includes openings (e.g., channels)112, which may be configured to allow vented gases to pass beyond thecarrier 92 and into a vent chamber, which is described in further detailherein with respect to FIG. 9. In certain embodiments, the openings 112may be a gap or space between the subassembly 80 and the housing 60. Inother embodiments, the openings 112 may be a gap or space between thevent shields 100 and 102 and the housing 60. In still furtherembodiments, the openings 112 may be holes or channels formed in thecarrier 92 itself The positioning of the shield plates 100 and 102relative to various electrical components of the module 28 isillustrated in further detail below in FIG. 7.

In FIG. 7, the carrier 92 is removed to more clearly illustrate theposition of the shield plate 100 relative to the sensing components 84and the cabling 90. In accordance with the illustrated embodiment, thevents 58 of the battery cells 54 of the cell stack 50 may be locatedbehind the shield plate 100 within the module housing 60. Accordingly,in certain embodiments, the shield plate 100 is located directly withinthe path 108 of the vented gases (e.g., directly within the ventingdirection of the cells 54) to absorb energy from the vented gases (e.g.,thermal and kinetic energy) to mitigate damage to the various electricalcomponents of the subassembly 80.

To enable the shield plates 100 and 102 to absorb such energy, theshield plates 100 and 102 may be formed or include any material capableof absorbing and/or quickly dissipating thermal energy from the ventedgases. Accordingly, the shield plates 100 and 102 may be formed usingmaterials having a low heat capacity (e.g., lower than the material ofthe carrier 92), such as aluminum, copper, or any other metallic,ceramic, polymeric, or composite material meeting desired thermalconductivity specifications. In certain embodiments, the vent shields100 and 102 may have an isotropic thermal conductivity that enables heatto be directed in a particular direction, such as laterally (e.g., alongthe plane of the vent shields 100 and 102) rather than in the samegeneral direction of venting (e.g., vent paths 108 and 110).Additionally or alternatively, the shield plates 100 and 102 may simplybe physical barriers that absorb a certain amount of kinetic and thermalenergy from the gases vented by the battery cells 54. In this way, thephysical impact and heat that would otherwise be imparted to the carrier92 is, to a large extent, deposited into the shield plates 100 and 102.

The modules 28 of the present disclosure may have a variety of ventingconfigurations that use the shield plates 100 and 102 described above.Generally, gases generated during a venting situation may be moved fromthe module housing 60, and out of a vent 120 of the battery module 28,as shown in FIG. 8. In certain embodiments, the module housing 60 mayinclude a module housing cover 122 (e.g., a lid) that includes the vent120. Specifically, gases generated in the interior of the module housing60 may be directed from the interior, into a venting chamber formed bythe housing 60 or the housing cover 122, and out of the module vent 120.As shown, the vent 120 may be in the form of a hose fitting, which mayinclude threads or barbs 124 to enable securement with a vent adapter, avent hose, or the like. The manner in which vented gases are expelledfrom the battery module 28 may be further appreciated with reference toFIG. 9.

FIG. 9 is a top view of the battery module of FIG. 8, with a top portionof the housing 60 (e.g., the housing cover 122) being made partiallytransparent to view certain internal features of the module 28 relativeto the cover. As shown in the illustrated embodiment, the carrier 92 andvarious internal surfaces 130 of the housing 60 may produce one or moreof the openings 112 that direct vented gases into a venting chamber 134.In other embodiments, the openings 112 may be created by gaps betweenthe internal surfaces 130 and the vent shields 100 and 102. In stillfurther embodiments, the openings 112 may be formed directly in thecarrier 92 (e.g., holes formed in the carrier). The venting chamber 134may be formed between the housing 60 or housing cover 122 and thesubassembly 80. Therefore, the subassembly 80 may partially define theventing chamber 134. In certain embodiments, the subassembly 80 may forma bottom wall (e.g., a floor) of the venting chamber 134, such that thesubassembly 80 blocks the effluent from flowing back towards the batterycells 54. In other embodiments, the bottom wall (e.g., a floor) of theventing chamber 134 may include the vent shields 100 and/or 102. Oncethe effluent reaches the venting chamber 134, gases may then be expelledout of the vent 120, as mentioned above.

As shown in FIG. 10, the vent pathway 108 may extend from the batterycell vents 58, and into the shield plates 100 and/or 102, which absorb amajority of the kinetic and thermal energy from the vented gases thatcould otherwise damage the electrical components of the subassembly 80.The vented gases may then pass over the shield plates 100 and 102, forexample through the openings 112, and into the venting chamber 134. Thegases are then expelled in a direction of expulsion 136 defined by thevent 120.

FIG. 11 further illustrates the vent path 108 of the effluent from thebattery cells 54. As shown in the illustrated embodiment, effluent flowsupwards (e.g., substantially parallel to the first 76 and second 78sides of the battery cells 54) and out of the vents 58. However, theeffluent eventually reaches, and is redirected by, the vent shield 100.Accordingly, the effluent is directed through the opening(s) 112 andinto the venting chamber 134. In certain embodiments, the effluent mayaccumulate in the venting chamber 134 until a pressure in the ventchamber increases to a point where the effluent is urged through thevent 120 and out of the battery module 28 (e.g., the pressure in theventing chamber 134 is greater than the pressure outside the batterymodule 28 or a threshold pressure associated with opening the vent 120is reached). In other embodiments, the effluent may simply flow throughthe venting chamber 134 and out the vent 120 rather than accumulating toany substantial degree in the venting chamber 134.

In certain embodiments, the vent shield 100 absorbs the thermal andkinetic energy from the effluent thereby mitigating any damage to thesensing components 84 of the integrated sensing and bus bar subassembly80 even though the effluent eventually passes over the sensingcomponents 84 after it flows through the channel(s) 112.

Moreover, as can be seen in FIG. 11, the vent shield 100 may have afirst surface 150 and a second surface 152, where the second surface 152is opposite the first surface 150. The first surface 152 is directly inthe flow path 108 of the effluent and contacts the effluent as it exitsthe cell vents 58. The first surface may initially absorb the kineticand thermal energy of the effluent and then disperse such energythroughout the remainder of the vent shield 100 (e.g., to a space in thevent shield 100 between the first 150 and second 152 surfaces or to thesecond surface 152). In certain embodiments, the second surface 152 maybe configured to define the venting chamber 134. As shown in theillustrated embodiment of FIG. 11, the second surface 152 creates thebottom wall (e.g., floor) of the venting chamber 134. The second surface152 may also be proximate to, or incorporated in, the subassembly 80,such that the second surface 152 contacts the effluent at the same timeas the sensing components 84 of the subassembly 80. Therefore, althoughthe second surface 152 may increase in temperature as a result of thethermal and kinetic energy being transferred from the first surface 150,the second surface 152 may not directly contact the effluent until afterthe effluent flows through the opening(s) 112 and into the ventingchamber 134.

Similarly, FIG. 12 illustrates the vent paths 108 and 110 of theeffluent from a top view of the battery module 28. The illustratedembodiment shows the battery module 28 including the first stack 50 ofbattery cells 54, the second stack 52 of battery cells 54, the firstvent shield 100 (e.g., disposed directly above the first stack 50 ofbattery cells 54), and the second vent shield 102 (e.g., disposeddirectly above the second stack 52 of battery cells 54). For example,the effluent exits the cells 54 via the cell vents 58. As shown in theillustrated embodiment, effluent flows upwards (e.g., substantiallyperpendicular to the first 100 and second 102 vent shields) and out ofthe vents 58. However, the effluent eventually reaches, and is blockedby, the vent shields 100 and 102. Accordingly, the effluent may flowthrough the opening 112 and/or a second opening 160 into the ventingchamber 134. It should be noted that although the effluent from thefirst stack 50 of battery cells 54 is illustrated as flowing through theopening 112, the effluent from the first stack 50 may flow through theopening 112, the second opening 160, or both. Similarly, the effluentfrom the second stack 52 of battery cells 54 may flow through theopening 112, the second opening 160, or both. In certain embodiments,the effluent may accumulate in the venting chamber 134 until a pressurein the vent chamber increases to a point where the effluent is urgedthrough the vent 120 and out of the battery module 28 (e.g., thepressure in the venting chamber 134 is greater than the pressure outsidethe battery module 28). In other embodiments, the effluent may simplyflow through the venting chamber 134 and out the vent 120 rather thanaccumulating in the venting chamber 134.

In view of the foregoing, it should be appreciated that one or more ofthe disclosed embodiments, alone or in combination, may be useful forproviding the technical effect of reducing thermal and physical stressesplaced on certain electronic components of a battery module. Forexample, in one aspect, it is now recognized that battery cells in abattery module may vent, and the vented materials may physically impacta carrier onto which certain electrical components are integrated. It isalso now recognized that the vented materials may also impart thermalenergy to the electrical components, and the physical and thermalstresses thereby placed upon the electrical components may result indegradation thereof, reducing the reliability and/or lifetime of thebattery module. To mitigate these unwanted effects and to provide otheradvantages and technical effects, the present disclosure utilizes a ventshield integrated onto a carrier of the electrical components that isplaced along a venting path between the battery cell vent and theelectrical components, thereby enabling the vent shield to absorb anddissipate kinetic and thermal energy from the gases.

The specific embodiments described above have been shown by way ofexample, and it should be understood that these embodiments may besusceptible to various modifications and alternative forms. It should befurther understood that the claims are not intended to be limited to theparticular forms disclosed, but rather to cover all modifications,equivalents, and alternatives falling within the spirit and scope ofthis disclosure.

What is claimed is:
 1. A battery module, comprising: a housing; a firststack of battery cells disposed in the housing, wherein each batterycell of the first stack of battery cells comprises a battery cellterminal and a battery cell vent, the battery cell terminal and thebattery cell vent are on an end of each battery cell, and the batterycell vent is configured to exhaust battery cell effluent into thehousing; a first vent shield plate disposed in the housing and directlyalong an immediate vent path of the battery cell effluent; a firstsurface of the first vent shield plate configured to direct the batterycell effluent to an opening between the first vent shield plate and thehousing; a second surface of the first vent shield plate opposite thefirst surface; a venting chamber fluidly coupled to the opening and atleast partially defined by the second surface; and a vent fluidlycoupled to the venting chamber and configured to direct the battery celleffluent out of the battery module.
 2. The battery module of claim 1,wherein the first vent shield plate comprises a first material and thehousing comprises a second material.
 3. The battery module of claim 2,wherein the first material has a lower heat capacity than the secondmaterial.
 4. The battery module of claim 3, wherein the first ventshield plate comprises a metal or a ceramic, and the housing comprises apolymer.
 5. The battery module of claim 1, comprising a second stack ofbattery cells disposed in the housing and adjacent to the first stack ofbattery cells and a second vent shield plate disposed in the housing anddirectly along an immediate vent path of battery cell effluent exhaustedfrom the second stack of battery cells.
 6. The battery module of claim5, wherein the second vent shield plate directs the battery celleffluent exhausted from the second stack of battery cells to the ventingchamber.
 7. The battery module of claim 1, comprising an integratedsensing and bus bar subassembly disposed in the housing and proximate tothe second surface of the first vent shield plate, wherein theintegrated sensing and bus bar subassembly comprises a sensor configuredto enable sensing of a voltage across the integrated sensing and bus barsubassembly or sensing of a temperature at the integrated sensing andbus bar subassembly.
 8. The battery module of claim 7, wherein theintegrated sensing and bus bar subassembly partially defines the ventingchamber.
 9. The battery module of claim 7, wherein the first surface ispositioned before the sensor along the vent path of the battery celleffluent, such that the first vent shield plate is configured to absorbkinetic energy and thermal energy from the battery cell effluent beforethe battery cell effluent reaches the sensor.
 10. The battery module ofclaim 9, wherein the battery module is configured to reduce the batterycell effluent from a first temperature when the battery cell effluent isexhausted from battery cells of the first stack of battery cells to asecond temperature when the battery cell effluent contacts the sensor.11. The battery module of claim 7, wherein the integrated sensing andbus bar subassembly comprises a carrier and a bus bar integrated ontothe carrier and configured to electrically couple battery cells of thefirst stack of battery cells in an electrical arrangement.
 12. Thebattery module of claim 7, wherein the sensor is electrically coupled toa controller and the controller is configured to disconnect a flow ofelectricity from the battery module to a load when the sensor sends asignal that includes a temperature or voltage that exceeds a thresholdvalue stored in the controller.
 13. The battery module of claim 1,wherein the venting chamber is partially defined by the housing.
 14. Thebattery module of claim 1, wherein the first stack of battery cellscomprises lithium-ion battery cells.
 15. A battery module, comprising: astack of lithium-ion battery cells disposed in a housing, wherein eachlithium-ion battery cell of the stack of lithium-ion battery cellscomprises a battery cell terminal and a battery cell vent, the batterycell terminal and the battery cell vent are on an end of eachlithium-ion battery cell, and the battery cell vent is configured toexhaust battery cell effluent into the battery module; a vent shieldplate disposed directly along an immediate vent path of the battery celleffluent; a first surface of the vent shield plate configured to directthe battery cell effluent to an opening between an edge of the shieldplate and the housing; and a second surface of the vent shield plateopposite the first surface; a vent structure configured to direct thebattery cell effluent out of the battery module; a venting chamber ofthe vent structure fluidly coupled to the opening and at least partiallydefined by the second surface; and a vent fluidly of the vent structurecoupled to the venting chamber.
 16. The battery module of claim 15,wherein the vent shield plate comprises a first material and the housingcomprises a second material, the first material having a lower heatcapacity than the second material.
 17. The battery module of claim 16,wherein the first vent shield comprises a metal or a ceramic, and thehousing comprises a polymer.
 18. The battery module of claim 16,comprising a sensor disposed on the second surface of the vent shieldplate, wherein the sensor is electrically coupled to a controller andthe controller is configured to disconnect a flow of electricity fromthe battery module to a load when the sensor sends a signal thatincludes a temperature or voltage that exceeds a threshold value storedin the controller.
 19. A battery module, comprising: a housing; areceptacle of the housing configured to receive a stack of batterycells, wherein each battery cell of the stack of battery cells has anend comprising a battery cell terminal and a battery cell vent, and thebattery cell vent is configured to exhaust battery cell effluent; anintegrated sensing and bus bar subassembly positioned directly along avent path of the battery cell effluent; a carrier of the integratedsensing and bus bar subassembly; a bus bar of the integrated sensing andbus bar subassembly integrated onto the carrier and configured toelectrically couple battery cells of the stack of battery cells in anelectrical arrangement; a sensor of the integrated sensing and bus barsubassembly disposed on the bus bar and configured to enable sensing ofa voltage across the bus bar or sensing of a temperature at the bus bar;a vent shield plate of the integrated sensing and bus bar subassemblydisposed on the carrier between the battery cells of the stack ofbattery cells and the sensor disposed on the bus bar, wherein the ventshield plate is configured to absorb kinetic energy and thermal energyfrom the battery cell effluent and to direct the battery cell effluentto an opening in the integrated sensing and bus bar subassembly; and amodule cover disposed over the integrated sensing and bus barsubassembly and against the housing, wherein the module cover and theintegrated sensing and bus bar subassembly at least partially define aventing chamber configured to receive the battery cell effluent afterthe battery cell effluent has passed through the opening, and whereinthe module cover comprises a vent configured to direct the battery celleffluent out of the battery module.
 20. The battery module of claim 19,wherein the vent shield plate comprises a first material and the housingcomprises a second material.
 21. The battery module of claim 20, whereinthe first material has a lower heat capacity than the second material.22. The battery module of claim 21, wherein the vent shield patecomprises a metal or a ceramic, and the housing comprises a polymer. 23.The battery module of claim 19, wherein the battery cell effluentcontacts the sensor.
 24. The battery module of claim 19, wherein thesensor is electrically coupled to a controller and the controller isconfigured to disconnect a flow of electricity from the battery moduleto a load when the sensor sends a signal that includes a temperature orvoltage that exceeds a threshold value stored in the controller.